Flame retardant bedding product and method of making same

ABSTRACT

A flame-retardant bedding product, such as a pillow or mattress topper, includes an inner core, an inner cover, and an outer cover. The inner cover covers the inner core. The inner cover comprises a knit fabric. The knit fabric has a weight of at least 225 grams per square meter (gsm). The outer cover covers the inner cover.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Section 111(a) application relating to and claiming the benefit of commonly owned, co-pending U.S. Provisional Patent Application No. 63/353,940, filed on Jun. 21, 2022, entitled “FLAME RETARDANT PILLOW AND METHOD OF MAKING SAME,” the contents of which are incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to flame retardant fabrics used in bedding and sleep products, such as pillows and mattresses, and, more specifically, to thermally-insulating and flame-retardant covers for pillows and mattress or bed toppers.

BACKGROUND OF THE INVENTION

Each year in the United States, the ignition of mattresses, bedding, mattress toppers, and pillows in private residences and overnight accommodations results in hundreds of deaths and hundreds of millions of dollars in property losses. Heightened awareness of fire prevention has led to the development of standards and regulations directed to reducing the likelihood that such fires will occur. One approach to reducing the likelihood of fires is to use flame resistant fabrics as flame barriers in bedding and sleep products, including pillows and mattress or bed toppers.

SUMMARY OF THE INVENTION

In an embodiment, a flame-retardant bedding product includes an inner core, an inner cover, and an outer cover. The inner cover covers the inner core. The inner cover comprises a knit fabric. The knit fabric has a weight of at least 225 grams per square meter (gsm). The outer cover covers the inner cover.

In an embodiment, the flame-retardant bedding product is a pillow. In an embodiment, the flame-retardant bedding product is a mattress topper. In an embodiment, the flame-retardant bedding product is another flame-retardant product other than a pillow and a mattress topper.

In an embodiment, a flame-retardant bedding product includes an inner core, an inner cover, and an outer cover. In some embodiments, the inner cover covers the inner core. In some embodiments, the inner cover comprises a knit fabric. In some embodiments, the knit fabric has a weight of at least 225 grams per square meter (gsm). In some embodiments, the outer cover covers the inner cover.

In an embodiment, the knit fabric comprises a flame-retardant material. In an embodiment, the knit fabric comprises a flame-retardant rayon material. In an embodiment, the outer cover comprises a flame-retardant material. In an embodiment, the outer cover comprises a non-flame-retardant material. In an embodiment, the inner cover comprises at least one open end and a flap at the open end, the flap folded so that the inner cover covers the inner core. In an embodiment, the inner cover comprises at least one open end and a flap at the open end, the flap folded so that the inner cover completely covers the inner core.

In an embodiment, the knit fabric comprises a flame-retardant material, and the inner cover comprises at least one seam formed of a flame-retardant thread. In an embodiment, the flame-retardant thread comprises polyaramid. In an embodiment, the knit fabric comprises a flame-retardant material, and the inner core comprises at least one of fiber, feathers, and foam. In an embodiment, the knit fabric comprises rayon material. In an embodiment, the inner core comprises at least one of polyester fibers, duck down feathers, goose down feathers, polyurethan foam, and latex foam.

In an embodiment, the outer cover comprises a flame-retardant material. In an embodiment, the outer cover comprises the same flame-retardant material as the inner cover. In an embodiment, the outer cover comprises a different flame-retardant material than the inner cover. In an embodiment, the outer cover comprises a same non-flame-retardant material as the inner cover. In an embodiment, the outer cover comprises a different non-flame-retardant material than the inner cover. In an embodiment, both the outer cover and the inner cover comprise flame-retardant materials. In an embodiment, both the outer cover and the inner cover comprise non-flame-retardant materials.

In an embodiment, a method of forming a flame-retardant bedding product includes obtaining an inner core, obtaining an inner cover, obtaining an outer cover, covering the inner core with the inner cover, and covering the inner cover with the outer cover. The inner cover comprises a knit fabric. The knit fabric has a weight of at least 225 grams per square meter (gsm). In an embodiment, the knit fabric comprises a flame-retardant material. In an embodiment, the knit fabric comprises a flame-retardant rayon material. In an embodiment, covering the inner core with the inner cover comprises sewing the inner cover closed on all sides. In an embodiment, sewing the inner cover closed on all sides comprises sewing the inner cover closed with a flame-retardant thread.

In an embodiment, covering the inner core with the inner cover comprises placing the inner core within the inner cover that includes an opening with a flap, and folding the flap to thereby cover the entire inner core with the inner cover. In an embodiment, a flame-retardant mattress or bed topper includes an inner core, an inner cover, and an outer cover. The inner cover covers the inner core. The inner cover comprises a knit fabric. The knit fabric has a weight of at least 225 grams per square meter (gsm). The outer cover covers the inner cover. In an embodiment, a method of forming a mattress or bed topper includes obtaining an inner core, obtaining an inner cover, obtaining an outer cover, covering the inner core with the inner cover, and covering the inner cover with the outer cover. The inner cover comprises a knit fabric. The knit fabric has a weight of at least 225 grams per square meter (gsm).

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings, which are presented for the purpose of illustration rather than being drawn to scale, and in which:

FIG. 1 is an isometric top view of some embodiments of a pillow;

FIG. 2 is a cross-sectional view, taken along line I-I and looking in the directions of the arrows, of the pillow of FIG. 1 ;

FIG. 3 is an isometric top view of a mattress topper on a mattress in accordance with the invention; and

FIG. 4 is a cross-sectional view, taken along line III-Ill and looking in the direction of the arrows, of the mattress topper of FIG. 3 .

DETAILED DESCRIPTION OF THE DRAWINGS

In an embodiment, a flame-retardant bedding product according to the present invention includes an inner cover formed of a flame-retardant, thermally-insulating fabric. In an embodiment, the fabric minimizes or excludes fiberglass or other components that fragment to form irritating or toxic particles.

In an embodiment, the flame-retardant bedding product is a pillow. In an embodiment, the flame-retardant bedding product is a mattress topper. In an embodiment, the flame-retardant bedding product is a flame-retardant product other than a mattress topper, and other than a pillow.

In an embodiment, the flame-retardant, thermally-insulating fabric is a woven fabric. In an embodiment, the flame-retardant, thermally-insulating fabric is a non-woven fabric. In an embodiment, the flame-retardant, thermally-insulating fabric is a knit fabric.

In an embodiment, the flame-retardant, thermally-insulating fabric includes a batt which contains flame-retardant fibers. Examples of suitable flame-retardant fibers include, without limitation, flame-retardant rayon, polyaramids (e.g., NOMEX® or KEVLAR®), elastanes (e.g., polyurethane, SPANDEX®, LYCRA®), flame-retardant polyesters, and combinations thereof. As used herein, “flame-retardant rayon” includes inherently flame-retardant cellulosic fibers such as, without limitation, rayon with incorporated silica, and cellulosic fibers with incorporated flame thermally-retardant chemicals (e.g., phosphorous compounds). In some embodiments, the batt consists of flame-retardant rayon fibers. In some embodiments, the batt comprises a combination of flame-retardant rayon fibers and fibers made of one or more of polyaramids (e.g., NOMEX® or KEVLAR®), elastanes (e.g., polyurethane, SPANDEX®, LYCRA®), and flame-retardant polyesters.

In an embodiment of the flame-retardant, thermally-insulating fabric, 100% by weight of the fibers in the batt are inherently flame-retardant cellulosic fibers. In an embodiment, at least 40% by weight of the fibers in the batt are flame-retardant rayon fibers, based on the total weight of the batt, with the remainder being other flame-retardant fibers and/or non-flame-retardant fibers. In an embodiment, the batt is a blend of inherently flame-retardant cellulosic fibers with other flame-retardant and/or non-flame-retardant fibers. Exemplary blends include, without limitation, inherently flame-retardant cellulosic fibers with one or more of the following fiber types: polyaramids, polyesters, polyurethanes, or other elastanes, acrylics, modacrylics, non-flame-retardant cellulosic fibers (e.g., cotton or bamboo), wool, cashmere, or silk.

Further exemplary blends include inherently flame retardant cellulosic fibers and one or more of polyaramid fibers in the range of 0% to 30% of the total weight of the fibers, polyester fibers in the range of 0% to 20% of the total weight of the fibers, and modacrylic fibers in the range of 0% to 50% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers are in the range of 5% to 30% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers are in the range of 5% to 25% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers are in the range of 5% to 20% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers are in the range of 5% to 15% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers are in the range of 5% to 10% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers is 5% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers is 10% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers is 15% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers is 20% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers is 25% of the total weight of the fibers. In an embodiment, the blend of flame-retardant cellulosic fibers and one or more of polyaramid fibers is 30% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 0% to 20% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 5% to 20% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 10% to 20% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 15% to 20% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 5% to 15% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 5% to 10% of the total weight of the fibers. In an embodiment, the polyester fibers in the range of 10% to 15% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 0% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 5% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 10% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 15% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 20% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 25% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 30% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 35% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 40% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 45% to 50% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 10% to 40% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 20% to 40% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 30% to 40% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 10% to 30% of the total weight of the fibers. In an embodiment, the modacrylic fibers in the range of 20% to 30% of the total weight of the fibers.

In an embodiment of the flame-retardant, thermally-insulating fabric, the density of the fibers of the batt is in the range of from 1.5 denier to 7 denier. In an embodiment, the density of the fibers of the batt is in the range of from 1.5 denier to 6 denier. In an embodiment, the density of the fibers of the batt is in the range of from 1.5 denier to 5 denier. In an embodiment, the density of the fibers of the batt is in the range of from 1.5 denier to 4 denier. In an embodiment, the density of the fibers of the batt is in the range of from 1.5 denier to 3 denier. In an embodiment, the density of the fibers of the batt is in the range of from 3.5 to 5.5 denier. In an embodiment, the density of the fibers of the batt is in the range of from 4 to 5 denier.

In an embodiment, the batt is from 60% to 90% by weight of the total weight of the fabric. In an embodiment, the batt is from 70% to 90% by weight of the total weight of the fabric. In an embodiment, the batt is from 80% to 90% by weight of the total weight of the fabric. In an embodiment, the batt is from 60% to 80% by weight of the total weight of the fabric. In an embodiment, the batt is from 60% to 70% by weight of the total weight of the fabric. In an embodiment, the batt is from 75% to 85% by weight of the total weight of the fabric. In an embodiment, the batt is 80% by weight of the total weight of the fabric. In an embodiment, the batt is 70% by weight of the total weight of the fabric. In an embodiment, the batt is 60% by weight of the total weight of the fabric. In an embodiment, the batt is 90% by weight of the total weight of the fabric. In an embodiment, the batt is 95% by weight of the total weight of the fabric. In an embodiment, the batt is 99% by weight of the total weight of the fabric. In an embodiment, the batt is 100% by weight of the total weight of the fabric.

In an embodiment, the flame-retardant, thermally-insulating fabric does not include any binders or binding materials, such as thermoplastics or latexes.

In an embodiment, the weight of the flame-retardant, thermally-insulating fabric is in the range of 175 gsm to 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 200 gsm to 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 225 grams per square meter (gsm) to 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 300 grams per square meter (gsm) to 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 400 grams per square meter (gsm) to 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 175 grams per square meter (gsm) to 225 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 200 grams per square meter (gsm) to 225 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 225 grams per square meter (gsm) to 300 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 225 grams per square meter (gsm) to 400 grams per square meter (gsm). In an embodiment, the weight of the fabric is in the range of 225 grams per square meter (gsm) to 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is 175 grams per square meter (gsm). In an embodiment, the weight of the fabric is 200 grams per square meter (gsm). In an embodiment, the weight of the fabric is 225 grams per square meter (gsm). In an embodiment, the weight of the fabric is 300 grams per square meter (gsm). In an embodiment, the weight of the fabric is 400 grams per square meter (gsm). In an embodiment, the weight of the fabric is 500 grams per square meter (gsm). In an embodiment, the weight of the fabric is greater than 225 grams per square meter (gsm). In an embodiment, the weight of the fabric is less than 225 grams per square meter (gsm). In an embodiment, the weight of the fabric is greater than 300 grams per square meter (gsm). In an embodiment, the weight of the fabric is less than 300 grams per square meter (gsm). In an embodiment, the weight of the fabric is greater than 400 grams per square meter (gsm). In an embodiment, the weight of the fabric is less than 400 grams per square meter (gsm). In an embodiment, the weight of the fabric is less than 500 grams per square meter (gsm).

In an embodiment of the thermally-insulating fabric, the fabric is a coated fabric, wherein the coating is applied to the fabric. In an embodiment of the coated fabric, the coating includes one or more flame-retardant chemicals. In an embodiment of the coated fabric, the coating includes a nanoclay. In an embodiment of the coated fabric, the coating includes graphite. In an embodiment, the fabric does not have a coating.

In an embodiment, the batt includes inherently flame-retardant viscose fibers. In an embodiment, all of the fibers in the batt are flame retardant viscose fibers. In an embodiment, the batt includes a blend of fibers made from different materials. In an embodiment, the fibers of the batt include fibers that shrink when heated to a critical temperature specific to the material of the fiber. In an embodiment, the fibers of the batt consist of fibers that shrink when heated to a critical temperature specific to the material of the fiber.

In an embodiment, the fibers in the batt include fibers of different denier. In an embodiment, the fibers in the batt consist of fibers of approximately the same denier.

In an embodiment, the flame-retardant bedding product includes an inner core covered by the flame retardant, thermally-insulating fabric. Examples of suitable materials for the inner core include, without limitation, fibers including polyester fibers, feathers including duck down feathers and goose down feathers, foam including latex foam and polyurethane foam, springs including steel springs, and combinations thereof.

In an embodiment, the inner cover is sewn closed on all sides, to prevent removal of the inner core from within the inner cover without removing one or more sections of seam from the inner cover. In an embodiment, one or more of the seams is thread formed of flame-retardant fibers. Examples of suitable flame-retardant fibers include, without limitation, flame-retardant rayon, polyaramids (e.g., NOMEX® or KEVLAR®), elastanes (e.g., polyurethane, SPANDEX®, LYCRA®), flame-retardant polyesters, and combinations thereof. In an embodiment, all of the seams are thread formed of flame-retardant fibers. In an embodiment, one or more of the seams are thread formed of non-flame-retardant fibers. In an embodiment, one or more of the seams are thread formed of non-flame-retardant fibers. In an embodiment, all of the seams are thread formed of non-flame-retardant fibers. In an embodiment, the inner cover includes at least one open end with a flap, such that after placing the inner core within the inner cover, folding over the flap results in the inner cover covering the entire inner core. In an embodiment, the inner cover has a J-shaped flap. In an embodiment, the flap is sewn closed with flame-retardant or non-flame retardant thread. In an embodiment, the flap is not sewn closed.

In an embodiment, the inner cover causes the inner core of the flame-retardant bedding product to conform to a flame-retardancy standard that does not exceed a maximum heat release rate of 200 kW with a total heat release of 15 Mj (megajoules), similar to the requirements of CPSC 16 CFR 1633 testing methodology that is applied to mattresses. In an embodiment, the inner cover prevents ignition of the inner core when the flame-retardant bedding product, such as a pillow or mattress topper, is exposed to an open flame for one minute or less.

In an embodiment, the flame-retardant bedding product, such as a pillow or mattress topper, includes an outer cover that covers the inner cover. Examples of suitable materials for the outer cover include, without limitation, woven fabrics, non-woven fabrics, knit fabrics, and combinations thereof. In an embodiment, the outer cover is made from a flame-retardant, thermally-insulating fabric described above. In an embodiment, the outer cover is made from the same flame-retardant, thermally-insulating fabric as the inner cover. In an embodiment, the outer cover is made from a different flame-retardant, thermally-insulating fabric than the inner cover. In an embodiment, the outer cover is not made from a flame-retardant, thermally-insulating fabric. In an embodiment, the outer cover comprises a same non-flame-retardant material as the inner cover. In an embodiment, the outer cover comprises a different non-flame-retardant material than the inner cover. In an embodiment, both the outer cover and the inner cover comprise flame-retardant materials. In an embodiment, both the outer cover and the inner cover comprise non-flame-retardant materials.

In an embodiment, the flame-retardant characteristic of the flame-retardant bedding product, such as a pillow or mattress topper, does not negatively impact any or all of the feel, performance, aesthetics, and durability of any or all of the flame-retardant bedding product itself, the inner core, the inner cover, and the outer cover.

The figures show two embodiments of flame-retardant bedding products—a pillow, and a mattress topper. FIG. 1 is an embodiment of flame-retardant pillow 100 including the above-described flame-retardant, thermally-insulating fabric, according to an embodiment of the present invention, and FIG. 2 is an embodiment of pillow 100. FIGS. 3 and 4 , discussed below, are embodiments of flame-retardant mattress topper 200 including the above-described flame-retardant, thermally-insulating fabric, according to an embodiment of the present invention.

Referring to FIGS. 1 and 2 , the pillow 100 includes an inner cover 110, an inner core 120, and an outer cover 130. In an embodiment, the inner cover 110 includes a thermally-insulating flame-retardant fabric 111, such as one or more thermally-insulating flame-retardant fabric discussed above.

As shown in the figures, the pillow 100 include the inner core 120 covered by the inner cover 110. In an embodiment, the inner cover 110 covers the inner core 120 directly—that is, without any additional layer disposed between the inner cover 110 and the inner core 120. In an embodiment, there are one or more additional layers (not shown) between the inner cover 110 and the inner core 120. In an embodiment, the inner core 120 includes an inner-core material such as one or more of those discussed above.

Also as shown in the figures, the pillow 100 include the outer cover 130 covering the inner cover 110. In an embodiment, the outer cover 130 covers the inner cover 110 directly—that is, without any additional layer disposed between the outer cover 130 and the inner cover 110. In an embodiment, there are one or more additional layers (not shown) between the outer cover 130 and the inner cover 110. In an embodiment, the outer cover 130 includes an outer-core material such as one or more of those discussed above. In an embodiment, the outer cover 130 may be covered by another layer. In an embodiment, the outer cover 130 is covered by a sham. In an embodiment, the outer cover 130 is covered by a pillowcase.

Referring to FIGS. 3 and 4 , the mattress topper 200 includes the inner cover 210, the inner core 220, and the outer cover 230, disposed on top of a mattress 201. In an embodiment, the inner cover 210 includes a thermally-insulating flame-retardant fabric 211, such as one or more thermally-insulating flame-retardant fabric discussed above.

As shown in the figures, the mattress topper 200 include the inner core 220 covered by the inner cover 210. In an embodiment, the inner cover 210 covers the inner core 220 directly—that is, without any additional layer disposed between the inner cover 210 and the inner core 220. In an embodiment, there are one or more additional layers (not shown) between the inner cover 210 and the inner core 220. In an embodiment, the inner core 220 includes an inner-core material such as one or more of those discussed above.

Also as shown in the figures, the mattress topper 200 include the outer cover 230 covering the inner cover 210. In an embodiment, the outer cover 230 covers the inner cover 210 directly—that is, without any additional layer disposed between the outer cover 230 and the inner cover 210. In an embodiment, there are one or more additional layers (not shown) between the outer cover 230 and the inner cover 210. In an embodiment, the outer cover 230 includes an outer-core material such as one or more of those discussed above. In an embodiment, the outer cover 230 may be covered by another layer. In an embodiment, the outer cover 230 is covered by a sheet. In an embodiment, the outer cover 230 is covered by a blanket. In an embodiment, the outer cover 230 is covered by a duvet. In an embodiment, the outer cover 230 is covered by a comforter. In an embodiment, the outer cover 230 is covered by a bedspread.

In an embodiment, the inner core 220 may comprise a foam material. The foam material may comprise a foam material that is 3 inches in thickness. The foam material may comprise a foam material that no greater than 5 inches in thickness. The foam material may be sized to be disposed on a top surface of the mattress 201. The foam material may be able to be rolled for transport, and unrolled for placement on the mattress 201. The foam material may comprise a rectangular shape. Thus, by this arrangement, the flame-retardant mattress topper 200 may be disposed on the top (that is, sleeping surface) of the mattress 201. In some embodiments, the mattress 201 may be a twin-size mattress, a full-size mattress, a queen-size mattress, a king-size mattress, a California-king-size mattress, or any other size mattress.

Although not shown in the drawings, in some embodiments, the mattress topper 200 may include a skirt or other material to retain the mattress topper 200 on the mattress 201.

In some embodiments, the disclosure may be applied to other bedding and/or sleep products. In an embodiment, a blanket, a duvet, and/or a comforter may have the structure of the disclosed flame-retardant pillow, including the disclosed inner cover, the disclosed inner core, and/or the disclosed outer cover.

It should be understood that the embodiments described herein are merely exemplary in nature and that a person skilled in the art may make many variations and modifications thereto without departing from the scope of the present invention. All such variations and modifications, including those discussed above, are intended to be included within the scope of the embodiments. 

What is claimed is:
 1. A flame-retardant bedding product, comprising: an inner core; an inner cover wherein the inner cover comprises a knit fabric, wherein the knit fabric has a weight of at least 225 grams per square meter (gsm), and wherein the inner cover covers the inner core; and an outer cover, wherein the outer cover covers the inner cover.
 2. The flame-retardant bedding product of claim 1, wherein the bedding product comprises a pillow or a mattress topper.
 3. The flame-retardant bedding product of claim 1, wherein the knit fabric comprises a flame-retardant rayon material.
 4. The flame-retardant bedding product of claim 1, wherein the outer cover comprises a flame-retardant material.
 5. The flame-retardant bedding product of claim 1, wherein the outer cover comprises a non-flame-retardant material.
 6. The flame-retardant bedding product of claim 1, wherein the inner cover comprises at least one open end and a flap at the open end, the flap folded so that the inner cover covers the inner core.
 7. The flame-retardant bedding product of claim 1, wherein the knit fabric comprises a flame-retardant material, and the inner cover comprises at least one seam formed of a flame-retardant thread.
 8. The flame-retardant bedding product of claim 7, wherein the flame-retardant thread comprises polyaramid.
 9. The flame-retardant bedding product of claim 1, wherein the knit fabric comprises a flame-retardant material, and wherein the inner core comprises at least one of fiber, feathers, and foam.
 10. The flame-retardant bedding product of claim 9, wherein the knit fabric comprises rayon material.
 11. The flame-retardant bedding product of claim 10, wherein the inner core comprises at least one of polyester fibers, duck down feathers, goose down feathers, polyurethan foam, and latex foam.
 12. The flame-retardant bedding product of claim 11, wherein the outer cover comprises a flame-retardant material.
 13. The flame-retardant bedding product of claim 12, wherein the outer cover comprises a material that is the same as the flame-retardant material of the inner cover.
 14. The flame-retardant bedding product of claim 12, wherein the outer cover comprises a non-flame-retardant material.
 15. A method, comprising the steps of: obtaining an inner core; obtaining an inner cover; wherein the inner cover comprises a knit fabric, wherein the knit fabric has a weight of at least 225 grams per square meter (gsm). obtaining an outer cover; covering the inner core with the inner cover; and covering the inner cover with the outer cover to form a bedding product.
 16. The method of claim 15, wherein the bedding product comprises a pillow or a mattress topper.
 17. The method of claim 15, wherein the knit fabric comprises a flame-retardant rayon material.
 18. The method of claim 15, wherein covering the inner core with the inner cover comprises sewing the inner cover closed on all sides.
 19. The method of claim 15, wherein sewing the inner cover closed on all sides comprises sewing the inner cover closed with a flame-retardant thread.
 20. The method of claim 15, wherein covering the inner core with the inner cover includes placing the inner core within the inner cover that includes an opening with a flap, and folding the flap to thereby cover an entirety of the inner core with the inner cover. 